Patent application title: SEALED, SOLDERLESS I/O CONNECTOR

Abstract:

A sealed, solderless I/O connector for allowing the connection of cables
or desk accessories to a mobile communication device while providing a
weather tight seal allowing the use of the mobile communication device
outdoors. The sealed, solderless I/O connector provides for greater
tolerance of mechanical stress due to vibration or dropping because the
contact points between the connector and the printed circuit board
accomplished with a "U" shaped spring contact. The sealed, solderless I/O
connector also provides a locking mechanism to prevent unintended
detachment of the cable or desk accessory.

Claims:

1. A sealed, solderless I/O connector for facilitating the connection of a
cable or a desk accessory to an electronic device, the apparatus
comprising:a plurality of electrically conductive connector terminals for
making electrical connections with the cable contacts or cradle accessory
contacts on one end and with connector mating pads on a printed circuit
board on the other end;a plurality of connector caps for providing a base
to mount a plurality of connector retainers;a plurality of connector
retainers for providing a locking mechanism for attached cables or cradle
accessories;a connector housing for assembling the connector terminals,
connector caps and connector retainers into a connector body assembly;a
connector lock with threaded receivers for securely attaching the
connector body to the printed circuit board; anda plurality of connector
screws for securing the connector lock to the printed circuit board by
passing the connector screws through holes in the printed circuit board
and connector body and threading the connector screws into the threaded
receivers in the connector lock, wherein a tension created between the
connector terminals and connector mating pads upon securing the connector
lock to the printed circuit board using the plurality of connector screws
closes an electrical circuit between the connector terminals and the
connector mating pads.

2. The apparatus of claim 1, the connector terminals are comprised of an
alloy of beryllium and copper suitable for electrically conductive
applications.

3. The apparatus of claim 1, the connector terminals have a first bend on
one end for facilitating an electrical connection with a cable contact or
a cradle accessory contact.

4. The apparatus of claim 3, the first bend is an "L" shaped bend on one
end of about ten percent of the total length to an angle of about ninety
degrees for facilitating an electrical connection with a cable contact or
a cradle accessory contact.

6. The apparatus of claim 5, the contamination resistant seal facilitates
the prevention of moisture and dust particles from entering the
electronic device through the connector terminals.

7. The apparatus of claim 3, the connector terminals have a second bend in
a direction opposite the first bend for facilitating an electrical
connection with contacts on a printed circuit board.

8. The apparatus of claim 7, the second bend is a "U" shaped bend of about
ten percent of the length of the connector terminal in a direction
opposite the first bend beginning about the center of the remaining
length of the connector terminal and forming the "U" shape in a direction
away from the first bend.

9. The apparatus of claim 1, the connector caps are insert molded into the
connector housing forming a contamination resistant seal.

11. The apparatus of claim 1, the connector retainer locking mechanism
further comprises a locking clip for securely attaching a cable or cradle
accessory to the connector.

12. The apparatus of claim 11, the locking clips are insert molded into
the connector retainer forming a contamination resistant seal.

13. The apparatus of claim 11, the locking clips are comprised of a zinc
alloy suitable for the mechanical stress of repetitive flexing during
locking and unlocking.

16. The apparatus of claim 1, the connector lock further comprises a ridge
running lengthwise along the longer dimension of the connector lock for
compressing the connector terminals against the connector mating pads.

17. The apparatus of claim 16, the ridge compresses the connector
terminals at a position along the end of the connector terminals opposite
the end with the first bend.

20. A method of creating a sealed, solderless connection on a printed
circuit board for a mobile communication device, the method
comprising:placing a connector body on a printed circuit board adjacent
to the printed circuit board connector body mounting holes and the
connector mating pads;aligning the connector mounting holes in the
connector body and the printed circuit board;inserting a connector lock
into the connector body and compressing the connector terminals against
the connector mating pads; andinserting the connector screws from the
side opposite the connector body through the printed circuit board and
the connector body and into the threaded receivers in the connector lock
to securely attach the connector body to the printed circuit board.

21. A sealed, solderless I/O connector, the apparatus comprising:means for
making electrical connections with a cable or desk accessory on one end
and with connector mating pads on a printed circuit board on the other
end;means for providing a base to mount a plurality of connector
retainers;means for providing a locking mechanism for attached cables or
desk accessories;means for assembling the electrical connectors, the base
and the locking mechanism; andmeans for securely attaching the connector
to the printed circuit board andmeans for closing an electrical circuit
between the cable or desk accessory on the one end and the connector
mating pads on the printed circuit board.

22. The apparatus of claim 21, further comprising means for attaching
additional components.

23. The apparatus of claim 21, further comprising means for aligning the
connector with the printed circuit board.

24. The apparatus of claim 21, further comprising means for sealing the
connector to a mobile communication device case.

Description:

TECHNICAL FIELD

[0001]The subject invention relates generally to communication devices,
and more particularly to connectors attached to circuit boards for
connecting cables to communication devices.

BACKGROUND

[0002]Communication devices such as cellular telephones have become a
necessary tool carried by almost every member of modern society. The
portable nature of the device has led to a market trend to make the
device smaller and therefore less cumbersome to carry no matter what the
dress or situation. The miniaturization of the device has continued on
all fronts, including connectors for attaching cables to the
communication device such as for providing power to recharge the
batteries in the mobile device or connect the mobile device to other
computing resources.

[0003]A combination of the miniaturization of the communication device and
its associated connectors and the heavy cycles of use associated with a
device that is used everyday therefore requiring continuous attachment
and detachment of the external cables to the connectors has exposed a
problem in the design of the connectors. Connectors are traditionally
attached to the circuit boards by a soldered connection. Although the
soldered connection facilitates a good electrical connection for the
transmission of current for recharging or communication signals, the
smaller size of the connectors and the frequency of use have produced
systemic problems of failure of the connectors because of the mechanical
stresses associated with attaching and removing the cable from the
connector.

[0004]Once a connector has failed, usually resulting in a break of one or
more of the soldered connections, the communication device is only viable
until the current battery charge is depleted. Attempting to repair a
connector is not feasible by the end user and the expense of returning
the communication device for repair is usually prohibitive because
replacing the connector requires replacing the connector and the attached
circuit board. In some cases repair is not possible because of the design
of the communication device and a new communication device must be
purchased as a replacement.

[0005]This scenario is upsetting to the communication device user because
the communication device can fail in this manner after relatively little
use because of an errant force exerted on the connector because the user
became entangled in the cable and pulled to hard while the cable was
connected to the communication device. In this scenario, the
communication device still operates as intended but its useable life is
now limited by the amount of charge remaining in the battery.

[0006]Market demand has created the requirement for smaller communication
devices with a connector capable of withstanding the greater cycles of
use and errant forces associated with a device that is used on a
continuous basis. In another aspect, market pressure is also demanding
connectors more tolerant of high moisture conditions. The connector is
expected to survive the everyday spill of a liquid, such as a cup of
coffee, or the splashing of raindrops so attaching the cable to the
connector after one of these types of events does not produce an
electrical short capable of destroying the device because the fluid was
able to reach the circuit board from the connector access port.

SUMMARY

[0007]The following presents a simplified summary in order to provide a
basic understanding of some aspects described herein. This summary is
neither an extensive overview nor is intended to identify key/critical
elements or to delineate the scope of the various aspects described
herein. Its sole purpose is to present some concepts in a simplified form
as a prelude to the more detailed description presented later.

[0008]The subject innovation includes an injection molded connector body
containing connector terminals sealed into the connector body, an
injection molded connector lock containing threaded retainers for
sandwiching the connector terminals between the connector lock and the
connector mating pads located on the printed circuit board and connector
screws for securing the connector lock, connector body and printed
circuit board together. The connector does not require soldering because
the tension created between the connector terminals and the connector
mating pads by tightening the connector screws provides sufficient
contact to close the electrical circuit between the connector terminals
and the connector mating pads. The subject innovation also allows the
connector to flex under external forces produced by the user while
connecting and disconnecting cables or by stress induced by dropping the
communication device containing the connector.

[0009]In another aspect of the subject innovation, the connector 's
injection molded design of molding the connector terminals into the
connector body provides a sufficiently water tight connector to allow the
use of the connector in outdoor communication devices. In another aspect,
the connector incorporates two locking features for positively
maintaining a connection to an attached cable or desk accessory. As with
the connector terminals, the locking mechanism is also molded into the
connector body to provide a durable and watertight seal.

[0010]To the accomplishment of the foregoing and related ends, certain
illustrative aspects are described herein in connection with the
following description and the annexed drawings. These aspects are
indicative of various ways which can be practiced, all of which are
intended to be covered herein. Other advantages and novel features may
become apparent from the following detailed description when considered
in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011]FIG. 1 illustrates an embodiment of the components of a sealed,
solderless I/O connector body including the connector housing, connector
terminals, connector cap and connector retainer.

[0012]FIG. 2 illustrates an embodiment of the components of a sealed,
solderless I/O connector including the connector lock, connector body,
printed circuit board with connector mating pads and the connector
screws.

[0017]Systems and methods are provided enabling the attachment of a
connector to a printed circuit board and creating an electrical
connection without the use of solder. The design and assembly of the
connector also provides a water and dust resistant barrier allowing the
connector's use in outdoor applications where water or dust can be of
sufficient magnitude to prohibit the use of other connectors without this
barrier. The solderless design of the connector provides a greater level
of resistance to shock and vibration because there are no soldered
connections between the connector and the printed circuit board. The
solderless design also provides for the easy replacement of the connector
should the connector become damaged from external forces or use. The
simple removal of two screws allows for the connector 's removal and
replacement.

[0018]In one aspect of the subject disclosure, the sealed, solderless I/O
connector increases the useful life of the mobile communications device
by providing a connector with a greater resistance to abuse by the user.
For example, the design of the connector intends for the user to insert
the cable for charging the battery in a direction parallel and on axis
with the insertion pins of the cable. The user does not always insert the
cable as directly as possible and in some cases, flexes the cable and the
connector to a point of cracking soldered connections in the process.

[0019]It should be noted that although useful for describing the
invention, the subject innovation is not limited to mobile communication
devices. The sealed, solderless I/O connector is equally applicable to
any computing device, mobile or stationary. It should also be noted that
although useful for describing the subject invention, the sealed,
solderless I/O connector is not limited to connecting cables to a
computing device. The sealed, solderless I/O connector is applicable to
any external connection to the computing device requiring an electrically
conductive connection capable of withstanding repetitive attachment and
detachment of a harsh nature. Examples of a harsh nature of attachment or
detachment include not only severe flexing of a connected cable but also
include "angry" slamming of a mobile computing device into a charge
cradle or dropping the mobile computing device in a manner where it lands
on the sealed, solderless I/O connector.

[0020]As used herein, cradle accessory includes but is not limited to wall
mount charge/communication cradles, vehicle charge/communication cradles
and forklift charge/communication cradles. The term cradle accessory is
intended to reflect an external connection from an electrically
conductive device to the sealed, solderless I/O connector attached to the
printed circuit board of the mobile computing device

[0021]In another example, after connecting the cable the user can
accidently become entangled in the cable, drop the mobile communication
device or even forget the mobile communication device is connected to the
cable while using the mobile communication device and move a sufficient
distance to reach the limits of the cable length and apply sufficient
force perpendicular to the axis of insertion to break the soldered
connection between a soldered connector and a printed circuit board.

[0022]The subject innovation allows the mobile communication device to be
much more tolerant of these common scenarios. In one aspect, because the
connector is not soldered to the printed circuit board, a greater amount
of connector flexing is permitted because there are no soldered
connections to fracture. In another aspect, if sufficient force is
applied to break the connector then the connector is easily replace
because the removal of two screws allows the connector 's removal without
the difficult and sometimes damaging step of removing solder to free the
connector from the printed circuit board.

[0023]As used herein, the term to "infer" or "inference" refer generally
to the process of reasoning about or inferring states of the system,
environment, user, and/or intent from a set of observations as captured
via events and/or data. Captured data and events can include user data,
device data, environment data, implicit and explicit data, etc. Inference
can be employed to identify a specific context or action, or can generate
a probability distribution over states, for example. The inference can be
probabilistic, that is, the computation of a probability distribution
over states of interest based on a consideration of data and events.
Inference can also refer to techniques employed for composing
higher-level events from a set of events and/or data. Such inference
results in the construction of new events or actions from a set of
observed events and/or stored event data, whether or not the events are
correlated in close temporal proximity, and whether the events and data
come from one or several event and data sources.

[0024]Referring initially to FIG. 1, an exploded view of connector body
100 of a sealed, solderless I/O connector for a mobile communication
device is depicted. The connector body is comprised of a connector
housing 102, a plurality of connector terminals 104, a plurality of
connector caps and a plurality of connector retainers. In one aspect of
the subject innovation, the connector body 100 includes one connector
housing 102 insert molded with seven connector terminals 104, two
connector caps 106 and two connector retainers 108.

[0025]In one aspect of the subject innovation, the connector terminals
104, connector caps 106 and connector retainers 108 are all insert molded
into the connector housing 102. This process provides a connector body
that is sufficiently rigid and structurally stable to allow a secondary
function as an internal mounting bracket. For example, an antenna or a
microphone can be mounted to the installed sealed, solderless I/O
connector by molding, clamping or screwing the component to the connector
body.

[0026]In another aspect of the subject innovation illustrated by FIG. 1,
the insert molded nature of the assembly of the connector housing 102,
connector terminals 104, connector caps 106 and connector retainers 108
provides a weather tight seal sufficiently water and dust tight to allow
a user to operate a mobile communication device employing the sealed,
solderless I/O connector outdoors without the fear of damaging the mobile
communication device by the infiltration of moisture or dust particles
through the external connector.

[0027]In another aspect of the subject innovation, the connector housing
102 is molded from a liquid crystal polymer material suitable for
injection molding. The U shaped design of the connector housing 102
provides for an orientation of the cable connection point at the base of
the U in a direction parallel to the plane of the printed circuit board
212 and extending off the end of the printed circuit board 212. The ends
of the U shaped connector housing are injection molded with holes for the
passage of screws through holes 214 in the printed circuit board 212 the
connector housing 102 and into the threaded holes on the connector lock
208.

[0028]FIG. 1 illustrates another aspect of the subject innovation at the
connector terminals 104. The connector terminals 104 are constructed of a
conductive material suitable for withstanding the stress of sandwiching
the connector terminals between the connector mating pads 206 and the
connector lock 208 and for repetitive stress generated by the continual
insertion and removal of the external cable. For example, in one
manufacture, the connector terminals can be constructed of an alloy of
beryllium and copper suitable for use in electrically conductive
applications. The connector terminals 104 are insert molded into the
connector housing 102.

[0029]In one aspect of the subject invention, the connector terminals are
L shaped 110 in design with approximately ten percent of the length of
each terminal bent to approximately a ninety degree angle forming an L
shape 110. The L shaped 110 bend in the connector terminal is the contact
point between the connector terminal and the pin inserted with by the
cable attaching to the sealed, solderless I/O connector.

[0030]In another aspect of the subject innovation, approximately two
thirds of the way from the L shaped 110 bend towards the opposite end of
the connector terminal, a U shape 112 is formed in the connector terminal
in a direction opposite to the direction of the L shaped 110 bend. The U
shaped 112 bend in the connector terminal is the contact point between
the connector terminal and the connector mating pad 206 located on the
printed circuit board 212. It should be noted that the width of the
connector housing and the number of connector terminals can vary with the
requirements of the application and manufacturing.

[0031]In another aspect of the subject innovation, connector caps 106 are
insert molded into the connector housing 102. The connector caps are
manufactured from a liquid crystal polymer material suitable for
injection molding. The connector caps 106 are inserted in the connector
housing to provide a stable mounting position for the connector retainers
and to provide a seal against moisture and dust attempting to infiltrate
the mobile communication device through the sealed, solderless I/O
connector.

[0032]In another aspect of the subject innovation, connector retainers 108
are insert molded into the connector housing 102. The connector retainers
108 are manufactured from a liquid crystal polymer suitable for injection
molding and include a zinc alloy retaining clip 114 for securely
attaching a cable or desk accessory. The connector retainers are placed
over the connector caps 106 in the assembly. The connector retainers 108
provide a locking mechanism by including a spring like retaining clip 114
for positively securing the cable or desk accessory to the sealed,
solderless I/O connector.

[0033]Referring next to FIG. 2, an exploded view 200 of a sealed,
solderless I/O connector is illustrated. The sealed, solderless I/O
connector comprises a connector body 202, a connector lock 208 and
connector screws 210 to secure the components to the printed circuit
board 212. The connector body 202 is place against the side of the
printed circuit board with the connector mating pads 206. When the holes
204 in the arms of the connector body 202 are aligned with the holes 214
in the printed circuit board 212, the connector terminals 104 will align
with the connector mating pads 206 on the printed circuit board 212. The
connector lock 208 then applies force on the connector terminals 104
securing them against the connector mating pads 206 with sufficient force
to create a reliable connection. The connector lock 208 has a ridge
running lengthwise along the longer dimension of the connector lock 208
on the side inserted into the connector body 202 for applying the force
necessary to sufficiently compress the connector terminals 104 against
the connector mating pads 206. The connector lock 208 is held in this
position by the connector screws 210 inserted from the opposite side of
the printed circuit board 212 and screwed into the threaded retainers 216
on the connector lock 208.

[0034]Referring next to FIG. 3, a cutaway view of the connector body 202
attached to the printed circuit board 212 is illustrated. In one aspect
of the subject innovation, the connector terminals 104 are in contact
with the connector mating pads 206 at the "U" shaped bend 112 in the
connector terminals 104. In another aspect, the holes in the connector
body 202 are aligned with the connector mounting holes 214 in the printed
circuit board 212. Once the mounting holes are aligned, the connector
terminals 104 are also aligned with and directly over the connector
mating pads 206.

[0035]In another aspect of the subject innovation, after final assembly,
including attaching the connector lock 208 over the connector terminals
104 with the connector screws 210, it is evident that the electrical
connection created between the connector terminals 104 at the "U" shaped
112 bend and the connector mating pads 206 is stable. If a substantial
force is applied to the connector, as in an accidental drop of the mobile
communication device, the contact points between the connector terminals
104 and the connector mating pads 206 simply roll on the "U" shaped 112
bend in the connector terminals 104 on the connector mating pads 206. The
contact point between the connector terminals 104 and the connector
mating pads 206 does not have a rigid solder connection that would be
susceptible to fracture under the described stress.

[0036]Referring next to FIG. 4, a sealed, solderless I/O connector body
202 attached to a printed circuit board 212 is illustrated. In one aspect
of the subject innovation, the connector lock 208 maintains constant
pressure on the connector terminals 104 as a result of tightening the
connector screws 210 into the threaded receivers 406 molded into the
connector lock 208. The flat surface of the connector body 202 adjacent
to the printed circuit board 212 provides a stable platform to minimize
the ability of the connector body 202 to move and release the pressure
applied by the connector lock 208 on the connector terminals 104. The
remaining ability of the connector body 202 to flex under stress has no
effect on the electrical connection between the connector terminals 104
and the connector mating pads 206 because the connector terminals 104 are
not soldered to the connector mating pads 206. In another aspect of the
subject innovation, the retaining clips 404 provide for a positive
locking connection between the connector body 202 and the attached cable
or cradle accessory. In another aspect, the flat rectangular area 408 of
the connector body provides a uniform and easily sealed mating area for
the mobile device case to attach to the connector body 202 to prevent the
intrusion of moisture or dust particles.

[0037]Referring now to FIG. 5, a typical mobile communication device is
illustrated with a sealed, solderless I/O connector installed. The design
of the printed circuit board 212 and the mobile communication device case
creates a flush mounting arrangement for the sealed, solderless I/O
connector. It should be noted that although the representations of the
sealed, solderless I/O connector illustrates seven contacts, the sealed,
solderless I/O connector can have a fewer or a greater number of contacts
resulting in a narrower, wider or stacked arrangement of contacts.

[0038]Referring now to FIG. 6, a method 600 of attaching a sealed,
solderless I/O connector to a printed circuit board 212 is described. In
one aspect of the method beginning at step 602, a connector body 202 is
placed against the printed circuit board. The connector body 202 is
placed on the side of the printed circuit board 212 containing the
connector mating pads 206. The connector body 202 is oriented so the
connector terminals 104 contact the connector mating pads 206.

[0039]In another aspect of the subject method 600 illustrated at step 604,
the connector terminals 104 are aligned with the connector mating pads
206 by aligning the attachment holes 204 in the connector body 202 with
the mounting holes 214 in the printed circuit board 212.

[0040]In another aspect of the subject method 600 illustrated at step 606,
the connector lock 208 is inserted into the connector body 202 above the
connector terminals 104. The connector lock 208 will sandwich the
connector terminals 104 against the connector mating pads 206 on the
printed circuit board 212. The connector lock form fits into a slot at
the rear of the connector body 202 and over the attachment holes 204 in
the connector body 202. A ridge formed in the connector lock 208 the
width of the connector terminals 104 applies sufficient force on the
connector terminals 104 at a position near the end of the connector
terminals 104 opposite the "L" shaped bend to maintain a stable
electrical connection between the connector terminals 104 and the
connector mating pads 206 located on the printed circuit board 212.

[0041]In another aspect of the subject method 600 illustrated at step 608,
the connector screws 210 are inserted through the holes 214 in the
printed circuit board from the side opposite the side adjacent to the
connector body 202. The connector screws 210 continue through the holes
in the connector housing 102 and into the threaded receivers in the
connector lock 208. The connector screws 210 are then tighten to a
sufficient torque to compress the connector lock 208 against the
connector housing 102 and therefore compressing the connector terminals
104 against the connector mating pads 206.

[0042]The word "exemplary" is used herein to mean serving as an example,
instance, or illustration. For the avoidance of doubt, the subject matter
disclosed herein is not limited by such examples. In addition, any aspect
or design described herein as "exemplary" is not necessarily to be
construed as preferred or advantageous over other aspects or designs, nor
is it meant to preclude equivalent exemplary structures and techniques
known to those of ordinary skill in the art. Furthermore, to the extent
that the terms "includes," "has," "contains," and other similar words are
used in either the detailed description or the claims, for the avoidance
of doubt, such terms are intended to be inclusive in a manner similar to
the term "comprising" as an open transition word without precluding any
additional or other elements.

[0043]The aforementioned systems have been described with respect to
interaction between several components. It can be appreciated that such
systems and components can include those components or specified
sub-components, some of the specified components or sub-components,
and/or additional components, and according to various permutations and
combinations of the foregoing. Sub-components can also be implemented as
components communicatively coupled to other components rather than
included within parent components (hierarchical). Additionally, it should
be noted that one or more components may be combined into a single
component providing aggregate functionality or divided into several
separate sub-components, and that any one or more middle layers, such as
a management layer, may be provided to communicatively couple to such
sub-components in order to provide integrated functionality. Any
components described herein may also interact with one or more other
components not specifically described herein but generally known by those
of skill in the art.

[0044]In view of the exemplary systems described above, methodologies that
can be implemented in accordance with the described subject matter will
be better appreciated with reference to the flowcharts of the various
figures. While for purposes of simplicity of explanation, the
methodologies are shown and described as a series of blocks, it is to be
understood and appreciated that the claimed subject matter is not limited
by the order of the blocks, as some blocks may occur in different orders
and/or concurrently with other blocks from what is depicted and described
herein. Where non-sequential, or branched, flow is illustrated via
flowchart, it can be appreciated that various other branches, flow paths,
and orders of the blocks, may be implemented which achieve the same or a
similar result. Moreover, not all illustrated blocks may be required to
implement the methodologies described hereinafter.

[0045]In addition to the various embodiments described herein, it is to be
understood that other similar embodiments can be used or modifications
and additions can be made to the described embodiment(s) for performing
the same or equivalent function of the corresponding embodiment(s)
without deviating therefrom. Accordingly, no single embodiment shall be
considered limiting, but rather the various embodiments and their
equivalents should be construed consistently with the breadth, spirit and
scope in accordance with the appended claims.

[0046]While, for purposes of simplicity of explanation, the methodology is
shown and described as a series of acts, it is to be understood and
appreciated that the methodology is not limited by the order of acts, as
some acts may occur in different orders and/or concurrently with other
acts from that shown and described herein. For example, those skilled in
the art will understand and appreciate that a methodology could
alternatively be represented as a series of interrelated states or
events, such as in a state diagram. Moreover, not all illustrated acts
may be required to implement a methodology as described herein.